Nanostructured Separator Element for Low-Resistance Cell Contact

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Solution Overview

Problem

Existing electrochemical cells face high contact resistance between components, which reduces efficiency, exacerbated by non-conducting surface layers formed in the chemical environment.

Innovation Solution

A separator element arrangement with elongated nanostructures, such as carbon or metallic nanostructures, extending into the diffusion layer to establish direct mechanical and electrical contact, improving the connection between the separator element and the diffusion layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional separator elements are used without nanostructures, then the device complexity is low, but the contact resistance between separator element and diffusion layer is high

Engineering Contradiction:

Improvecontact resistanceVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The separator element surface is segmented into multiple elongated nanostructures (nanofibers, nanowires, or nanotubes) that extend into the diffusion layer. This segmentation creates numerous individual contact points between the separator element and diffusion layer, significantly reducing contact resistance through distributed electrical pathways while maintaining an organized structural pattern.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from a conventional planar separator element surface to a three-dimensional structure with nanostructures extending vertically into the diffusion layer. This dimensional change creates additional contact interfaces and pathways, enabling improved electrical contact without increasing the planar footprint of the separator element.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If elongated nanostructures are added to the separator element, then the electrical contact is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improveelectrical contactVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The elongated nanostructures act as intermediary elements between the separator element and the diffusion layer. These nanostructures serve as conductive bridges that facilitate electrical contact while being integrable into existing manufacturing processes through techniques such as electrospinning, chemical vapor deposition, or self-assembly methods that can be applied to separator element production.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If non-conducting surface layers form on components, then the chemical stability is improved, but the contact resistance increases

Engineering Contradiction:

Improvechemical stabilityVSAvoidcontact resistance

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The elongated nanostructures provide continuous conductive pathways that penetrate through or bypass non-conducting surface layers that may form on components. By extending into the diffusion layer, the nanostructures maintain uninterrupted electrical contact despite the presence of insulating surface films, ensuring continuous electrical functionality while preserving chemical stability.

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This arrangement significantly reduces contact resistance and enhances the mechanical and electrical contact between the separator element and the diffusion layer, leading to improved efficiency in electrochemical cells like fuel cells and electrolyzers.

Implementation Method 1

The separator element comprises a plurality of elongated nanostructures, at least some of the elongated nanostructures being arranged to connect the separator element to the diffusion layer by extending into the diffusion layer

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Implementation Method 2

The elongated nanostructures are thus placed in direct contact with the diffusion layer, which improves the mechanical and electrical contact between the diffusion layer and the separator element

Methodology Applied

Scientific EffectMechanical Contact: Friction

Data Source

PatentUS20240290993A1A separator element arrangement for an electrochemical cell comprising a nanostructure

Publication Date: 2024.08.29 SMOLTEK AB

AI summary

A separator element arrangement for an electrochemical cell is presented. The separator element arrangement comprises a separator element and a diffusion layer arranged adjacent to the separator element. The separator element comprises a plurality of elongated nanostructures. At least some of the elongated nanostructures are arranged to connect the separator element to the diffusion layer by extending into the diffusion layer.